Polaris trail boss 325 Manuals

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Polaris trail boss 325 Service Manual

Polaris trail boss 325 Service Manual (666 pages)

Brand: Polaris | Category: Offroad Vehicle | Size: 15.13 MB

Table of Contents

Table of Contents
2
General Information / Specifications
2
Chapter 1 General Information / Specifications

4
- Engine Serial Number Location
  4
- Machine Model Number and VIN Number Location
  4
- Model / VIN Identification
  4
- 1999 Publication Part Numbers
  6
- Standard Torque Specifications
  8
- Conversion Table
  10
  - Metric Tap Drill Sizes
    11
  - SAE Tap Drill Sizes
    11
- Tap Drill Charts
  11
- Service Tips
  12
- Glossary of Terms
  13
- Glossary of Terms
  14
- Special Tools
  16
- 1999 Model Specifications
  17
  - Trail Blazer
    17
  - Trail Boss 250
    19
  - Xpress 300
    21
  - Xplorer 300
    23
  - Sportsman 335
    25
  - Sport 400
    28
  - Scrambler 400
    29
  - Scrambler 500
    30
  - Magnum 500
    36
- 1999 Model Specifications
  36
  - Trail Blazer
    41
  - Xplorer 4X4
    43
  - Trail Boss 325
    45
  - Xpedition 325
    51
  - Sportsman 335
    53
  - Xplorer 400
    55
  - Scrambler 400 2X4
    57
  - Scrambler 400 4X4
    59
  - Xpedition 425
    61
  - Magnum 500
    63
  - Scrambler 500
    65
  - Sportsman 6X6
    69
  - Maintenance
    72
Chapter 2 Maintenance

74
- Periodic Maintenance Chart
  74
  - Pre-Ride / Daily Inspection
    75
  - Recommended Lubricants - Quick Reference
    76
  - Polaris Premium Lubricant and Maintenance Product Part Numbers
    77
  - Lubrication
    79
  - Lubrication - Shaft Drive Models
    81
  - Lubrication Chart - Shaft Drive Models
    82
  - Gearcase Lubrication - Quick Reference
    83
  - Front Gearcase Lubrication
    84
  - Rear Gearcase Lubrication
    86
    
    Dipstick Models
    87
    
    Transmission Lubrication
    87
    
    Shaft / Chain Models Without Dipstick
    88
    
    Counter Balance Oil Changing Procedure
    89
    
    Counter Balancer Lubrication (400Cc Engines)
    89
    
    Procedure for Adding Oil (400)
    89
    
    Torque Stop Adjustment
    90
    
    Transmission Gearshift Linkage Adjustment, Preliminary Inspection
    90
    
    Shift Linkage Adjustment -High/Low/Reverse Transmissions
    91
    
    Shift Linkage Adjustment (High/Reverse Transmissions)
    93
  - Carburetor Adjustments
    94
    
    Choke (Enricher) Adjustment
    94
    
    Throttle Operation - All Models
    94
    
    Air Screw Adjustment
    95
    
    Pilot Screw Anti-Tamper Plug Removal
    96
    
    Pilot Screw (Idle Mixture) Adjustment Notes
    97
    
    Pilot Screw Adjustment - 335 4- -Stroke Models
    97
    
    Pilot Screw Adjustment - 425 / 500 4- -Stroke Models
    97
    
    Idle Speed Adjustment
    98
    
    Throttle Cable / Electronic Throttle Control (ETC Switch) Adjustment
    99
    
    Oil Pump Adjustment Procedure
    100
    
    Oil Pump Bleeding Procedure
    102
    
    Oil Pump Troubleshooting Procedure
    102
    
    Oil Filter (2 Strokes)
    103
    
    Fuel Filter
    104
    
    Fuel Lines
    104
  - Fuel System
    104
    
    Vent Lines
    104
    
    Carburetor Draining
    105
    
    Compression Test - 2 Stroke
    106
    
    Compression Test - 4 Stroke
    106
    
    Engine Mounts
    106
    
    Fastener Torque - Engine
    106
  - Battery Maintenance
    107
  - Electrical
    107
  - Electrical
    108
    
    Engine-To-Frame Ground
    108
    
    Ignition Timing
    108
    
    Spark Plug
    108
    
    Coolant Strength / Type
    109
    
    Cooling System Hoses
    109
    
    Liquid Cooling System Overview
    109
    
    Radiator
    109
    
    Coolant Level Inspection
    110
    
    Engine Cooling System
    111
    
    Radiator Coolant Level Inspection
    111
    
    Air Filter Service (Trail Blazer Style)
    112
    
    Dual Stage Air Cleaner - 300 Style
    113
    
    Primary Pre-Cleaner Foam Boot
    113
    
    Cleaning the Main Filter
    114
    
    Secondary (Main) Filter
    114
    
    Secondary Filter Removal and Installation
    114
  - Air Filter Service, 2 Stroke
    116
  - Air Filter Service, 4 Stroke
    116
  - Breather Filter
    116
    
    Air Box Sediment Tube
    117
    
    Breather Filter Inspection
    118
    
    Breather Hose
    118
  - Recoil Housing
    119
    
    Engine Oil Level (4 Stroke)
    120
    
    Oil and Filter Change (4 Stroke)
    120
    
    Valve Clearance - 335, 425, 500Cc Engines
    122
    
    Exhaust Valve Clearance Adjustment
    123
    
    Intake Valve Clearance Adjustment
    123
    
    Steering & Toe Alignment Inspection
    125
    
    Tie Rod End / Steering Inspection
    125
    
    Straightedge or String
    126
    
    Chalk
    127
    
    Toe Alignment Adjustment
    127
    
    Front Hub Fluid Change (AWD Models)
    128
    
    Front Hub Fluid Level Inspection (AWD Models)
    128
    
    Exhaust Pipe
    129
    
    Brake Pad Inspection
    130
    
    Brake System Inspection
    130
  - Brake System Service
    130
    
    Hose/Fitting Inspection
    130
    
    Auxiliary Brake Adjustment (Hydraulic)
    131
    
    Auxiliary Brake Adjustment - Mechanical
    132
    
    Auxiliary Brake Testing
    132
    
    Auxiliary Mechanical Brake System
    132
    
    Drive Chain and Sprocket Inspection
    133
    
    Drive Chain Inspection
    133
    
    Sprocket Inspection
    133
    
    Rear Drive Chain Tension Adjustment - Standard Swingarm
    134
    
    Rear Drive Chain Tension Inspection - Standard Swingarm
    134
    
    Adjustment Procedure - Concentric Swingarm Rear Axles (Tapered Roller Bearings)
    135
    
    Drive Chain Adjustment, Concentric Swingarm
    135
    
    Center/Front Drive Chain Inspection/Adjustment
    138
    
    Center/Front Drive Chain Slack Adjustment
    138
    
    6X6 Chain Inspection
    139
    
    6X6 Middle Axle Chain Adjustment
    139
    
    6X6 Rear Axle Drive Chain Adjustment
    139
    
    Drive Chain Inspection/Adjustment - 6X6
    139
    
    Controls
    140
    
    Front Suspension
    140
    
    Rear Suspension
    140
    
    Suspension Spring Preload Adjustment
    140
    
    Chassis Maintenance
    141
    
    Wheel Removal Front or Rear
    141
    
    Wheel, Hub, and Spindle Torque Table
    141
    
    Wheels
    141
    
    Frame, Nuts, Bolts, Fasteners
    142
  - Tire Inspection
    142
  - Tire Pressure
    142
  - Tire Tread Depth
    142
  - Engine
    144
  - Torque Specifications
    146
  - Engine Fastener Torque Patterns
    148
  - Piston Clearance Specifications (2 Stroke Engines)
    149
  - Piston Identification
    149
  - ES33PFE01 / 02 Engine Service Data
    150
  - EH42PLE02 / EH50PLE04, 06, 08, 09 Engine Service Data
    152
  - Bleed Hole Inspection
    154
  - Radiator Cap Pressure Test
    154
  - System Pressure Test
    154
CHAPTER 3 ENGINE Torque Specifications - 2 Stroke

155
- Cooling System Specifications
  155
  - Recommended Coolant
    155
  - Accessible Components - All Models
    156
  - Engine Removal
    156
    
    Engine Removal
    157
    
    Bleed Cooling System
    158
  - Engine Installation Notes
    158
    
    General Items
    158
    
    PVT System
    158
    
    EC25PF / EC28PF Engine Disassembly
    159
    
    Connecting Rod Side Clearance
    160
    
    Crankshaft Main Bearing Inspection
    160
    
    EC25PF/EC28PF Engine Assembly
    161
    
    Measure Crankshaft Width - - Bearings Installed
    161
    
    Oil Pump End Play Adjustment
    166
    
    Oil Check Valve Testing (EC25PF)
    167
    
    Oil Check Valve Testing (EC28PF)
    167
    
    Recoil Disassembly
    168
  - EC25PF Recoil Assembly
    169
  - EC38PL Engine Disassembly
    171
  - EC38PL Engine Inspection
    172
    
    Connecting Radial Clearance
    177
    
    Reed Valve Inspection
    178
    
    Water Pump Impeller Clearance
    178
    
    Impeller Spacer Shim Part Numbers
    179
    
    Oil Check Valve Testing (EC38PL)
    180
    
    Cylinder Inspection/Measurement
    181
    
    Piston Inspection/Measurement (2 Stroke)
    181
    
    Piston Ring Installed Gap
    182
    
    Cleaning the Cylinder after Honing
    183
    
    Cylinder Hone Selection/Honing Procedure
    183
    
    Honing to Oversize
    183
    
    Connecting Rod Small End Bearing Inspection
    184
  - Crankshaft Runout Inspection - 2 Stroke
    185
    
    Crankshaft Straightening
    185
    
    4 Stroke Engine Service
    186
    
    Engine Lubrication - ES33PF / EH50PL
    188
    
    Oil Pressure Test - ES33PF / EH50PL
    188
    
    Oil Flow -- ES33PF
    189
    
    335 (ES33PFE) Oil Flow Chart
    190
  - ES50PL Lubrication/Oil Flow
    191
  - EH50PL Oil Flow Chart
    192
  - Es33Pfengine Exploded View
    193
  - EH50PL Engine Exploded View
    194
    
    Cam Chain Tensioner/Rocker Arm/Camshaft Removal
    195
    
    Engine Disassembly / Inspection
    195
    
    To Position Crankshaft at Top Dead Center (TDC) on Compression Stroke
    195
    
    Cam Chain Tensioner Inspection
    196
  - ES33PF / EH50PL Engine Removal
    196
    
    Rocker Arm/Shaft Removal
    197
    
    Rocker Arm/Shaft Inspection
    198
    
    Camshaft Removal
    200
    
    Automatic Compression Release Installation
    202
    
    Automatic Compression Release Removal/Inspection
    202
    
    If Camshaft Is Installed in the Engine
    202
    
    If Camshaft Is Removed from Engine
    202
    
    Camshaft Inspection
    203
    
    Cylinder Head Exploded View, ES33PF
    204
    
    Cylinder Head Exploded View, EH50PL
    205
    
    Cylinder Head Inspection
    206
    
    Cylinder Head Disassembly
    207
    
    Cylinder Head Warpage
    207
    
    Valve Inspection
    209
    
    Combustion Chamber
    210
    
    Cylinder Head Reconditioning
    211
    
    Valve Guide Removal/Installation
    211
    
    Valve Seat Inspection
    211
    
    Reaming the Valve Guide
    212
    
    Valve Seat Reconditioning
    212
    
    Cylinder Head Assembly
    215
    
    Valve Sealing Test
    216
    
    Cylinder/Piston Removal and Inspection
    217
  - ES33PF / EH50PL Engine Bottom End Disassembly
    217
    
    Piston Removal
    219
    
    Cylinder Inspection
    220
    
    Piston-To-Cylinder Clearance
    221
    
    Crankcase Disassembly
    224
    
    Starter Drive Removal/Inspection
    224
    
    Flywheel/Stator Removal/Inspection
    225
    
    Cam Chain/Tensioner Blade
    226
    
    One Way Valve
    227
    
    Crankcase Separation
    228
    
    Oil Pump Removal/Inspection
    229
    
    Oil Pump Assembly
    231
    
    Counter Balancer Shaft Removal/Inspection
    232
    
    Crankshaft Removal/Inspection
    233
    
    Crankcase Bearing Inspection
    234
    
    Pump Shaft Oil Seal/ Water Pump Mechanical Seal Removal (Engine Disassembled)
    234
    
    Bearing Installation
    235
    
    Crankcase Assembly
    235
    
    Crankshaft End Play Adjustment
    236
    
    End Play Inspection/Adjustment
    236
    
    Counter Balancer Shaft End Play Adjustment
    238
    
    Pump Shaft
    239
    
    Pump Shaft Oil Seal Installation
    239
    
    Crankshaft, Counter Balancer, and Oil Pump Installation
    240
    
    Water Pump Mechanical Seal Installation (EH50PL)
    241
    
    Water Pump Mechanical Seal Removal - Engine Installed (EH50PL)
    241
    
    Cam Chain Drive Sprocket Installation
    243
    
    One Way Valve Installation
    243
    
    Tensioner Blade Installation
    243
    
    Piston Ring Installation
    244
    
    Piston Installation
    245
    
    Cylinder Installation
    246
    
    Cylinder Head Installation
    248
    
    Cam Chain/Camshaft Installation
    249
    
    Camshaft Timing
    249
  - ES33PF / EH50PL Engine Assembly/Inspection
    251
    
    Cam Chain Tensioner Installation
    252
    
    Stator, Flywheel and Starter Drive Installation
    252
    
    Flywheel
    253
    
    Starter Drive
    253
    
    Oil Pipes
    254
    
    Rocker Shaft/Rocker Arm Assembly Installation
    254
    
    Thermostat Installation
    254
    
    Recoil Disassembly/Inspection
    255
    
    To Complete Recoil Assembly
    257
    
    To Install a New Spring
    257
    
    To Reinstall an Old Spring
    257
    
    Spark Plug Fouling - 2 Stroke Engines
    258
    
    Spark Plug Fouling - 4 Stroke Engines
    258
  - Spark Plug Fouling Checklist
    258
    
    2 Stroke Engine Troubleshooting
    259
    
    Engine Does Not Turn over
    261
    
    Engine Idles but will Not Rev up
    261
    
    Engine Runs but will Not Idle
    261
    
    Engine Turns over but Fails to Start
    261
    
    Backfiring
    262
    
    Excessive Smoke and Carbon Buildup
    262
    
    Low Compression
    262
    
    EH42PL/EH50PL Cooling System Troubleshooting
    263
    
    Leak at Water Pump Weep Hole
    263
    
    Overheating
    263
    
    Temperature too Low
    263
    
    Fuel System/Carburetion
    264
    
    Air Screw (2 Cycle) / Pilot Screw (4 Cycle) Adjustment
    266
  - Main Jet Selection
    266
Chapter 4 Fuel System/Carburetion

266
- Jetting Guidelines
  266
  - Fuel Tank Assembly / Oil Tank Assembly
    267
  - Fuel Flow Diagrams
    269
    
    Fuel System Diagram - 2 Stroke Models
    269
    
    Fuel System Diagram - 4 Stroke Models
    269
    
    Air/Fuel Mixture Ratio
    272
    
    E-Clip Position Vs. Fuel Flow
    272
    
    Pilot Air Screw
    272
    
    Pilot Jet
    272
    
    Jet Needle
    273
    
    Needle Jet
    273
    
    Throttle Opening Vs. Fuel Flow
    273
  - Main Jet / Pilot Jet Part Numbers
    274
    
    Throttle Valve
    274
    
    Starter System - Closed Throttle (2 Cycle)
    275
    
    Pilot System (0-3/8 Throttle) (2 Cycle)
    276
    
    Slide Cutaway (1/8-3/8 Throttle) (2 Cycle)
    277
    
    Jet Needle/Needle Jet (3/8-3/4 Throttle) (2 Cycle)
    278
    
    Main System (3/4 to Full Throttle) (2 Cycle)
    279
  - Carburetor Component Function (2 Cycle)
    280
    
    Component Effect Vs. Throttle Opening (2 Cycle)
    280
    
    Mikuni Fuel Delivery (2 Cycle)
    280
  - Assembly, CV Carburetor
    281
  - Float Height Adjustment (2 Cycle)
    281
  - Needle and Seat Leakage Test - 2 Cycle
    281
  - Vent Systems (2 Cycle)
    281
  - Mikuni VM30SS / VM34SS Carburetor Exploded View
    282
  - 4 Cycle CV Carburetor System Function
    283
  - Vent Systems - 4 Cycle CV Carburetor
    283
  - Mikuni CV Carb Operation
    284
  - Pilot (Idle and Slow) System
    285
  - Starter System (Choke or Enrichment)
    285
  - Float System
    286
  - Main System
    286
  - Mikuni BST 34 Carburetor Exploded View
    287
  - Mikuni BST 40 Carburetor Exploded View
    288
  - Carburetor Disassembly Notes- Mikuni CV
    289
  - Carburetor Cleaning - Mikuni CV
    291
  - Carburetor Inspection - Mikuni CV
    292
  - Carburetor Assembly - Mikuni CV
    293
  - Carburetor Adjustment - Mikuni CV
    294
  - Float Height Adjustment
    294
  - Fuel Level
    295
Fuel Pump

296
- Needle and Seat Leakage Test
  295
- Fuel Pump Disassembly
  296
- Fuel Pump Inspection/Assembly
  296
- Fuel Pump Exploded View
  297
  - Fuel Starvation/Lean Mixture
    298
  - Poor Idle
    298
  - Troubleshooting
    298
  - Rich Mixture
    298
  - Erratic Idle
    299
  - Idle too Low
    299
  - Body / Steering / Suspension
    300
  - Torque Specifications, Special Tools
    302
  - Body Assembly Exploded View (Gen Ll - Typical)
    303
  - Front Cab Assembly
    303
  - Rear Cab Assembly
    303
  - Cover/Panel Removal (Gen Ll - Typical)
    304
  - Body Assembly Exploded View (Gen Lll - Typical)
    305
  - Cover/Panel Removal (Gen Lli - Typical)
    306
  - Body Assembly Exploded View (Gen Lv - Typical)
    307
  - Cover/Panel Removal (Gen Lv - Typical)
    308
  - Headlight Pod Exploded View (Gen Lv - Typical)
    309
  - Side Panel Removal (Gen Lv - Typical)
    310
  - Typical Steering Assembly, Exploded View, ’99 Trail Boss 250
    311
  - Steering Assembly, Exploded View, - 2X4 Models (Except ’99 Trail Boss 250)
    312
  - Steering Assembly, Exploded View All 4X4 and 6X6 Models
    313
  - A-Arm Replacement
    314
  - Concentric Swing Arm Removal
    315
  - Standard Swing Arm and Rear Suspension Exploded View
    317
  - Shaft Ride Swingarm Exploded View
    318
  - Shaft Ride Swingarm
    319
  - Swingarm Installation
    319
  - Rear Suspension Assembly, - Shaft Drive Models
    320
  - Rear Strut Stabilizer, 6X6 Models
    321
  - Rear Swing Arm Weldment, 6X6 Models
    322
  - Front Swing Arm Weldment, 6X6 Models
    323
  - Strut Assembly Exploded View - 2X4 Models
    324
  - Strut Assembly - AWD Models
    325
  - Front Strut Cartridge Replacement
    326
  - Front Strut Weldment Replacement
    326
  - Ball Joint Replacement
    327
  - Front Strut Ball Joint Replacement
    327
  - Decal Replacement
    330
  - Clutches
    332
  - Clutch Specifications
    334
  - PVT System Fastener Torques
    334
  - Special Service Tools and Supplies
    334
  - Drive Clutch Operation
    335
  - Driven Clutch Operation
    335
  - PVT Operation
    335
  - Standard PVT System Introduction
    335
CHAPTER 6 CLUTCHES Service Tools and Supplies

336
- PVT Maintenance/Inspection
  336
  - PVT Drying
    336
  - PVT Overheating
    336
  - PVT Sealing and Ducting Components
    336
  - PVT Disassembly
    337
  - PVT Assembly
    339
  - PVT Sealing and Ducting Components
    340
    
    Relationship of Drive Clutch Weights and Spring in Maintaining Operating RPM
    343
    
    Drive Clutch Spring Specifications
    344
  - Shift Weights
    345
  - Button to Tower Clearance Inspection
    346
  - Drive Clutch Inspection
    346
  - Shift Weight Inspection
    346
  - Drive Clutch & EBS Exploded View
    347
  - Drive Clutch Disassembly/Inspection
    348
    
    Moveable Sheave Bushing Inspection
    349
    
    Spider Removal
    349
    
    Roller, Pin and Thrust Washer Inspection
    350
  - Drive Clutch Assembly
    351
  - Standard P-90 (Non-EBS) Clutch
    353
  - Drive Belt Tension
    355
  - Drive Belt Removal/Inspection
    356
  - Clutch Alignment/Offset
    357
  - Drive Clutch Bushing Service
    359
    
    Drive Clutch Moveable Sheave - Bushing Removal
    359
    
    Polaris Kit PN 2871226
    359
    
    Drive Clutch Moveable Sheave - Bushing Installation
    360
    
    Drive Clutch Cover - Bushing Removal
    361
    
    Drive Clutch Cover - Bushing Installation
    362
  - Driven Clutch Disassembly/Inspection
    363
  - Driven Clutch Assembly
    366
  - Driven Clutch Bushing Service
    367
    
    Driven Clutch Moveable Sheave - Bushing Installation
    369
    
    Engine Braking System (EBS) Clutch
    372
    
    EBS Theory of Operation
    373
    
    Operation Guidelines for Ebs Clutches
    374
  - EBS Exploded View
    375
  - One-Way Clutch Inspection (Drive Clutch)
    376
  - Driven Clutch Disassembly/Inspection - EBS
    379
  - One-Way Clutch Preliminary Inspection (Driven)
    379
  - Ebs Clutch Bushing Removal and Installation
    383
  - Ebs Drive Clutch Moveable Sheave - Bushing Removal
    383
  - Removal and Installation Instructions
    383
  - EBS Clutch Cover - Bushing Installation
    384
  - EBS Clutch Cover - Bushing Removal
    384
  - EBS Drive Moveable - Bushing Installation
    384
  - EBS Driven - Bushing Installation
    385
  - EBS Driven - Bushing Removal
    385
  - EBS Driven - Backside (Outer) Bushing Installation
    386
  - EBS Driven - Backside (Outer) Bushing Removal
    386
  - Clutch Troubleshooting
    387
  - Final Drive
    390
  - Final Drive
    392
  - 2X4 Hub Bearing / Seal Replacement
    393
CHAPTER 7 FINAL DRIVE Final Drive Torque Specifications

393
- 2X4 Front Hub Disassembly/Inspection
  393
- 2X4 Front Hub Installation
  396
  - 2X4 Front Hub Assembly
    397
  - 2X4 Front Hub Exploded View
    397
  - AWD Operation Overview
    399
  - Electric Hub Engagement (AWD)
    399
  - AWD Front Hub Disassembly
    400
    
    Front Hub Removal (AWD)
    400
    
    Hub/Wheel Bearing Installation
    401
  - AWD Front Hub Bearing Adjustment
    402
  - AWD Front Hub Exploded View
    403
  - AWD Hub Seal Replacement
    405
  - AWD Magnetic Coil Service
    406
    
    Magnetic Coil Installation
    406
    
    Magnetic Coil Removal
    406
  - AWD Hilliard Clutch Disassembly/Inspection
    407
  - AWD Armature Plate Inspection
    408
  - AWD Front Drive Axle Removal
    409
  - AWD Front Drive Axle Installation
    410
    
    Driveshaft and CV Joint Handling Tips
    411
    
    Front Drive Shaft CV Joint Boot Replacement
    411
  - AWD Front Drive Axle Exploded View
    413
    
    Front Drive Axle Components
    413
    
    Front Prop Shaft Components
    413
    
    AWD Strut Casting Front Drive Axle Seal Replacement
    414
    
    Bearing Replacement Note for Front Drive Axle and Front Hub
    414
    
    Seal Sleeve Replacement
    415
    
    Seal Sleeve Tool
    415
  - AWD Front Prop Shaft Removal
    416
    
    U-Joint Disassembly (Typical)
    417
    
    U-Joint Service
    417
  - U-Joint Assembly
    418
  - AWD Front Housing Removal
    420
    
    Front Housing Disassembly
    420
    
    AWD Front Housing Identification
    421
  - AWD Front Housing Disassembly
    422
  - AWD Front Housing Identification
    422
  - AWD Front Housing Assembly
    424
  - AWD Front Housing Installation
    424
  - Front Housing Installation
    427
  - AWD Front Housing Exploded View
    428
    
    Rear Drive
    429
    
    Rear Axle Bend
    430
    
    Rear Drive Axle Service - Xpress / Xplorer 300
    430
    
    Rear Axle Installation
    431
    
    Rear Axle Removal
    431
    
    Concentric Swingarm Rear Axle Removal
    432
    
    Concentric Swingarm Rear Axle Installation
    434
    
    Concentric Swingarm Rear Axle Assembly, Exploded View
    435
    
    Concentric Swingarm Rear Axle Disassembly
    436
    
    Concentric Swingarm Rear Axle Assembly
    437
    
    Concentric Swingarm Rear Housing Removal
    438
    
    Concentric Swingarm Rear Housing Installation
    440
    
    Concentric Swingarm Rear Housing Service
    440
    
    Rear Housing Assembly/Bearing Service
    440
    
    Rear Housing Disassembly/Bearing Service
    440
    
    Rear Hub Inspection
    441
    
    Rear Axle Bearing Removal
    445
    
    Rear Axle Bearing Installation
    446
    
    Rear Hub/Bearing Carrier Removal
    447
  - Rear Hub Installation - Independent
    449
  - Rear Hub Disassembly - Independent
    450
  - Rear Hub Assembly - Independent
    451
  - Rear Drive Shaft Removal - Independent
    452
  - Rear Drive Shaft Installation
    454
  - Rear Drive Shaft Disassembly (U-Joint Style)
    455
    
    U-Joint Inspection - Rear Drive Shafts
    455
    
    Rear Drive Shaft Disassembly (Dual CV Joint Style)
    456
    
    CV Joint Assembly Procedure
    457
    
    Boot Installation
    458
    
    Boot Replacement
    458
    
    CV Joint Cleaning / Replacement
    458
    
    Independent Rear Suspension Exploded View
    459
  - Center Eccentric Housing Service
    460
    
    Tapered Bearing Center Eccentric Assembly Procedure
    460
    
    Front Eccentric Disassembly / Assembly Procedure
    461
  - Front Eccentric Housing Service
    461
    
    Front Eccentric Removal / Installation Procedure
    461
    
    Center / Front Chain Tightener Exploded View
    462
    
    Transmission Service
    464
  - Transmission Type Identification
    466
Chapter 8 Transmission Service

466
- Torque Specifications
  466
- Gear Shift Selector Removal
  467
- Gear Shift Selector Disassembly
  467
  - Gear Shift Selector Assembly
    469
  - Boot Replacement
    470
  - Gear Shift Selector Installation
    470
  - Type III, EZ Shift Transmission Assembly
    471
  - Type III, EZ Shift Transmission Disassembly
    471
  - Type III, EZ Shift Transmission Installation
    472
    
    Type III, EZ-Shift Transmission Installation (Typical)
    477
    
    Speedometer Service
    478
  - Type III, EZ Shift Transmission, Exploded View
    479
  - Type IV, Shaft Drive Transmission Assembly
    480
  - Type IV, Shaft Drive Transmission Disassembly
    480
  - Type IV, Shaft Drive Transmission Installation
    480
  - Type IV, Shaft Drive Transmission Removal
    480
    
    Transmission Installation
    484
    
    U Joint Style Shafts
    486
    
    Premium Synthetic Gear Case Lubricant
    487
    
    Rear Wheel Retaining Bolt Torque
    487
    
    Transmission Disassembly
    488
    
    Bushing Drive Tool
    496
    
    Bushing Installation, Transmission Center Shaft
    497
    
    Front Output Housing (Snorkel) Assembly
    497
    
    Final Installed Shaft End Play
    499
    
    Front Output Housing (Snorkel) Installation
    499
    
    Front Output Housing (Snorkel) Backlash Adjustment
    500
    
    Transmission Output Gear Backlash Inspection/Adjustment
    501
    
    Oil Deflector Screws
    505
    
    Tensioner Assembly - Top View
    506
    
    Tensioner Installation
    506
    
    View from Left Side of Transmission
    506
    
    Seal Installation Tool
    508
    
    Transmission Exploded View
    509
    
    Transmission Removal/Installation
    510
  - Type V, Shaft/Chain Transmission Assembly
    510
  - Type V, Shaft/Chain Transmission Disassembly
    510
    
    Remove Gear Indicator Switch(Es)
    511
    
    Transmission Assembly
    514
  - Type VI, Shaft Ride Transmission Assembly
    518
  - Type VI, Shaft Ride Transmission Disassembly
    518
  - Type VI, Shaft Ride Transmission Installation
    518
  - Type VI, Shaft Ride Transmission Removal
    518
    
    Transmission Exploded View
    526
    
    Transmission Troubleshooting Checklist
    527
    
    Brakes
    528
    
    Brakes Specifications
    530
    
    Brakes Torque Specifications
    531
    
    Brake Pad Basics
    532
  - Brake Pad Kits
    532
  - Brake System Service Notes
    532
  - Brake Noise Troubleshooting
    533
  - Hydraulic Brake System Operation
    534
    
    Typical Hydraulic Brake System
    534
    
    Dual Hydraulic Brake Caliper (DH Caliper)
    535
  - Dual Hydraulic Caliper Bleeding
    535
  - Brake Bleeding - Fluid Change
    537
  - Fluid Replacement/Bleeding Procedure
    537
    
    Master Cylinder Fluid Level
    538
    
    Reservoir Cover Torque
    538
  - Master Cylinder Disassembly
    539
  - Master Cylinder Inspection
    539
  - Master Cylinder Assembly
    541
  - Master Cylinder Installation
    542
  - Front Pad Removal
    544
  - Front Pad Brake Service
    545
  - Front Disc Inspection
    546
    
    Front Brake Disc Removal / Replacement
    547
    
    Caliper Disassembly
    548
  - Front Caliper Removal
    548
  - Front Caliper Disassembly
    549
  - Front Caliper Assembly
    550
  - Front Caliper Inspection
    550
  - Front Caliper Installation
    551
    
    Front Brake Caliper Exploded View
    552
    
    Brake Pad Removal
    553
    
    Dual Hydraulic Brake Caliper
    553
    
    Auxiliary Brake Master Cylinder Fluid Level
    554
    
    Brake Pad Installation
    554
    
    DH Brake Caliper
    554
    
    Dual Hydraulic Brake Caliper Removal/Inspection
    555
    
    Dual Hydraulic Brake Caliper Assembly
    556
    
    Caliper Mounting Bolt Torque
    557
    
    Dual Hydraulic Brake Disc Inspection
    558
    
    DH (Trans. Mounted) Caliper/Master Cylinder
    559
    
    DH (Rear Axle Mounted) Caliper/Master Cylinder
    560
    
    DH (Shaft Ride) Caliper/Master Cylinder
    561
    
    Auxiliary Brake Caliper Service (Mechanical) Disassembly
    562
    
    Auxiliary Brake Caliper Service (Mechanical) Assembly
    563
    
    Auxiliary Brake Caliper Service (Mechanical) Installation
    564
    
    Caliper Mount Bolt Torque
    564
    
    Polaris DOT 3 Brake Fluid
    564
    
    Auxiliary Brake Caliper (Mechanical)
    565
    
    Auxiliary Brake Caliper Mounting (Mechanical)
    566
    
    Brakes Squeal
    567
    
    Brakes Troubleshooting
    567
    
    Caliper Overheats (Brakes Drag)
    567
    
    Poor Brake Performance
    567
    
    Electrical Special Tools
    570
  - Headlamp Service, Gen II
    571
  - Headlamp Service, Gen III
    571
  - Headlamp Service, Gen IV
    571
    
    Headlight Adjustment (Gen II)
    571
    
    Headlight Lamp Replacement (Gen II)
    571
    
    Adjustment - Trail Blazer and Sport
    573
    
    Headlight Adjustment (Gen III -Scrambler, Trail Blazer and Sport)
    573
    
    Headlight Lamp Replacement (Gen III)
    573
    
    Trail Blazer and Sport
    573
    
    Scrambler
    574
    
    Headlamp Service - Gen Lv
    575
    
    Headlight Housing Replacement (Gen IV)
    575
    
    Headlight Lamp Replacement (Gen IV)
    575
    
    High Beam Headlight Adjustment (Gen IV)
    575
    
    Indicator Lamp Replacement (Gen II)
    576
    
    Indicator Lamp Replacement (Gen Lll and Gen IV)
    576
  - Indicator Lamp Service
    576
  - Taillight/Brakelight Lamp Replacement
    576
  - Timing Check Procedures
    577
    
    Typical 2-Stroke
    578
    
    Typical 4-Stroke
    578
  - Typical Ignition Timing Curves
    578
  - Crankshaft Degree to Piston Position Conversion
    579
  - Flywheel Identification
    580
    
    Flywheel Identification Stamp Location
    580
    
    Components of EC25/28PL 150 Watt Alternator (Exploded View)
    581
    
    Components of EC38PL 150 Watt Alternator (Exploded View)
    582
    
    Components of EC38PL 200 Watt Alternator (Exploded View)
    583
    
    Components of ES33PF/EH50PL 200 / 250 Watt Alternator (Exploded View)
    584
  - Ignition System Testing
    585
    
    CDI Output Test Using Peak Reading Adaptor
    586
    
    Cranking Output Test with Peak Reading Voltmeter
    586
  - Ignition System Troubleshooting
    587
    
    No Spark, Weak or Intermittent Spark
    587
    
    Battery Terminals/Terminal Bolts
    588
    
    Initial Battery Service
    588
    
    Battery Inspection/Removal
    589
    
    Battery Installation
    589
    
    Battery Testing
    589
    
    OCV - Open Circuit Voltage Test
    589
    
    Load Test
    590
    
    Specific Gravity Test
    590
    
    Charging Procedure
    591
    
    Electrolyte Freezing Points
    591
    
    Off Season Storage
    591
    
    Polaris Dielectric Grease
    591
  - Charging System Testing
    592
    
    Charging System
    593
    
    Charging System “Break Even” Test
    593
    
    Current Draw - Key off
    593
    
    Alternator Output Test (AC Amp)
    594
    
    Starter Motor Does Not Turn
    595
    
    Starter Motor Turns over Slowly
    595
  - Starter System Troubleshooting
    595
    
    Voltage Drop Testing
    596
    
    Starter Motor Disassembly (Typical)
    597
    
    Brush Inspection/Replacement
    598
    
    Armature Testing
    600
    
    Starter Assembly
    601
    
    Starter Motor Installation (EC38PL)
    601
    
    Pinion Gear - Anti Kick-Out Shoe, Garter Spring Replacement
    602
  - Starter Drive
    602
    
    Starter Solenoid Bench Test
    602
    
    Limiter Specifications
    603
    
    Speed Limiter System
    603
    
    Electronic Throttle Control (ETC) - Theory of Operation (Sportsman 335, Xplorer/Xpress 300, Trail Boss)(LR44)
    604
    
    Speed Limiter System - Theory of Operation (Sportsman 335, Xplorer/Xpress 300, Trail Boss)
    604
    
    Module Wire Color Function
    606
    
    Speed Limiter System Testing
    606
    
    Reverse Limit System
    607
    
    No Reverse Speed Limit
    608
    
    Reverse Speed Limit System
    608
    
    All Wheel Drive (AWD) Testing
    610
    
    No All Wheel Drive (AWD) on Shaft Drive Models Equipped with Hub Safety Module
    610
    
    No AWD in Reverse
    610
    
    All Wheel Drive System
    611
    
    Front Hub Engagement Limiter (Front Shaft Drive Models)
    611
    
    Hub Engagement Limiter RPM Test
    611
    
    Electronic Speedometer Troubleshooting Overview of Operation
    613
    
    Engine Run Time Hour Meter
    613
    
    Reverse Speed Limit (PVT Models Only)
    613
    
    Vehicle Speed and Odometer
    613
    
    Electronic Speedometer (Pvt Models)
    615
    
    No All Wheel Drive
    616
    
    No Speedometer And/Or Odometer Display
    616
    
    No High Speed Engagement Limit
    617
    
    No Reverse Speed Limit (Vehicle will Exceed 7-9Mph in Reverse)
    617
    
    Reverse Speed Limiter Activated in Forward Gear(S)
    618
    
    Wheel Speed Sensor
    618
    
    Reset Speedometer
    619
    
    Key Switch/Auxiliary Shut off (Kill) Switch
    621
    
    Override Button
    621
    
    Starter Switch
    621
    
    Switch Testing (Sportsman 335, Xplorer/Xpress 300, Trail Boss)
    621
    
    Gear Selector Switch/Neutral Light
    622
    
    Coolant Temperature Sensor Test (Hot Light)
    623
    
    Hot Light Circuit Test
    623
    
    Oil Level Sensor Testing (2 Stroke Models)
    623
    
    Oil Level Warning Light Testing (2 Stroke Models)
    623
  - Switch Testing
    623
    
    Oil Cooler Fan Circuit
    624
    
    Oil Cooler Fan Notes
    624
    
    Thermistor / LR60 Fan Control Test
    624
    
    Brake Light Switch
    625
  - Fan Motor Current Draw Test
    625
    
    Switch Testing
    625
    
    Gear Position Indicator Switch Test
    626
    
    Switch Continuity Table
    626
    
    Switch Schematic
    626
  - Electronic Throttle Control System Operation
    627
  - ETC Operation Test
    627
  - Wiring Diagrams
    629
  - Wiring Diagram 1999 Trail Blazer
    630
  - Wiring Diagram 1999 Trail Boss
    631
  - Wiring Diagram 1999 Xplorer 300 / Xpress 300
    632
  - Wiring Diagram 1999 Sportsman 335
    633
  - Wiring Diagram 1999 Sport 400
    634
  - Wiring Diagram 1999 Scrambler 400 (Early)
    635
  - Wiring Diagram 1999 Scrambler 400 (Late)
    636
  - Wiring Diagram 1999 Xplorer 400
    637
  - Wiring Diagram 1999 Scrambler 500
    638
  - Wiring Diagram 1999 Magnum 500
    639
  - Wiring Diagram 1999 Sportsman 500 / Sportsman 500 RSE
    640
  - Wiring Diagram 1999 Worker 500 (International)
    641
  - Wiring Diagram 1999 Big Boss 500 6X6
    642
  - Wiring Diagram 2000 Trail Blazer
    643
  - Wiring Diagram 2000 Xplorer 4X4
    644
  - Wiring Diagram 2000 Trail Boss 325
    645
  - Wiring Diagram 2000 Magnum 325 2X4
    646
  - Wiring Diagram 2000 Magnum 325 4X4
    647
  - Wiring Diagram 2000 Xpedition 325
    648
  - Wiring Diagram 2000 Sportsman 335 (Early)
    649
  - Wiring Diagram 2000 Sportsman 335 (Late)
    650
  - Wiring Diagram 2000 Xplorer 400
    651
  - Wiring Diagram 2000 Scrambler 400 2X4
    652
  - Wiring Diagram 2000 Scrambler 400 4X4
    653
  - Wiring Diagram 2000 Xpedition 425
    654
  - Wiring Diagram 2000 Magnum 500 (Early)
    655
  - Wiring Diagram 2000 Magnum 500 (Late)
    656
  - Wiring Diagram 2000 Scrambler 500 (Early)
    657
  - Wiring Diagram 2000 Scrambler 500 (Late)
    658
  - Wiring Diagram 2000 Sportsman 500 (Early)
    659
  - Wiring Diagram 2000 Sportsman 500 (Late)
    660
  - Index
    662

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Polaris trail boss 325 Owner's Manual

Polaris trail boss 325 Owner's Manual (189 pages)

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Brand: Polaris | Category: Offroad Vehicle | Size: 1.26 MB

Table of Contents

Table of Contents
11
Understanding Warnings
12
Safety Warning and Operation Decals
14
Daily Pre-Ride Inspection
23
Operation Warnings
24
Vehicle Identification Numbers
45
Control and Parts Functions
46
- Throttle Lever
  53
- Auxiliary Brake
  58
- Shifting Gears
  61
- Recoil Starter
  74
Starting the Engine
76
Starting the Engine
77
Vehicle Break in Period
78
Riding Gear
81
Carrying Loads
82
Daily Pre-Ride Inspection
85
Riding
86
- Making Turns
  87
- Traveling Downhill
  92
- Turning Around on a Hill
  93
- Crossing Streams
  94
- Trail Obstacles
  96
PVT System
100
Pvt Drying
101
Battery
103
Battery Removal
104
Noise Emission Control System Regulation
106
Maintenance
107
- Periodic Maintenance Schedule
  110
- Lubrication Recommendations
  118
- Steering Inspection
  130
- Toe Alignment
  130
- Front Brake
  132
- Spark Plugs
  142
- Tire Inspection
  162
- Wheel Installation
  162
  - Headlight Lamp Replacement
    166
  - High Beam Headlight Adjustment
    167
  - Headlight Adjustment
    168
- Storage Tips
  176
Carburetor Adjustments
179
Troubleshooting
180
Limited Warranty
184
Warranty
184
Index
187

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